Multilayer Gas Barrier Film for Thin Stable Oxygen Coatings
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Solution Overview
Problem
Gas barrier films with resin substrates and coating films formed using wet coating methods often exhibit unstable oxygen barrier properties, particularly when the coating film thickness is reduced, leading to inferior oxygen barrier performance due to defects caused by anti-blocking agents.
Innovation Solution
A gas barrier film design featuring a resin substrate with multiple layers, where the surface layer does not contain anti-blocking agents, and an inorganic oxide layer is included between the substrate and the oxygen barrier coating film, ensuring uniform coating application and minimizing gas permeation defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the coating film thickness is reduced, then the manufacturing cost and material usage are reduced, but the oxygen barrier properties deteriorate due to defects caused by anti-blocking agents
Solution Approach 1:
The invention extracts and removes anti-blocking agents from the surface layer of the resin substrate. By taking out these harmful components that cause defects, the coating film can achieve uniform application and proper thickness without interruptions, thereby maintaining good oxygen barrier properties even at reduced thickness levels.
Solution Approach 2:
The resin substrate is divided into multiple layers with different functions: the surface layer excludes anti-blocking agents to ensure coating quality, while inner layers may contain anti-blocking agents for their intended purpose. This segmentation allows optimization of each layer's composition for its specific function.
2Ease of operation
If anti-blocking agents are included in the resin substrate, then blocking is prevented, but coating uniformity deteriorates due to defects at the coating interface
Solution Approach 1:
The invention applies local quality by having different compositional characteristics in different regions of the resin substrate. The surface layer specifically excludes anti-blocking agents to ensure coating uniformity, while inner layers maintain anti-blocking agents for their blocking prevention function. Each layer has optimized local properties suited to its specific role.
3Quantity of substance
If the coating film is made thin, then the production cost and material consumption are reduced, but the oxygen barrier performance becomes unstable
Solution Approach 1:
The invention performs preliminary action by removing anti-blocking agents from the surface layer before coating application. This preparatory step ensures that the coating interface is free from defects that would compromise thin film integrity, allowing the coating film to achieve and maintain stable oxygen barrier properties even at reduced thickness.
Data Source
Figure 1~2
Figure 3
AI summary
A gas barrier film includes a resin substrate and an oxygen barrier coating film in contact with a first surface of the resin substrate. The resin substrate includes two or more resin layers including a base layer. Of the two or more resin layers, a resin layer forming the first surface of the resin substrate does not contain an anti-blocking agent.